Apparatus for producing wax match shafts

ABSTRACT

Apparatus for producing wax match shafts, comprising a shaping die having an aperture at least part of which has a polylateral, preferably a quadrilateral, cross-sectional configuration with convex sides.

Waited States Patent Kessier 1 Sept. 11, 1973 APPARATUS FOR PRODUCINGWAX MATCH SHAFTS Republic of South Africa Assignee: Chet Industries(Proprietary) Limited, Transvaal, Republic of South Africa Filed: Sept.22, 1971 Appl. No.: 182,645

Related US. Application Data Division of Ser. No. 863,948, Oct. 6, 1969,Pat. No. 3,626,047.

Foreign Application Priority Data Oct. 14, 1968 South Africa 68/6627 US.Cl 425/93, 93/84 R, 425/302,

425/324, 425/383 Int. Cl B311 l/00 17a 16 10 [.5 [4 1610a ./06. 106 10C37 58 39 15a 19 155 19 5c i je [58] Field of Search 425/93, 112, 383,425/396, 302, 324, 328, 343; 264/136, 145, 280; 93/1 C, 82, 84

[56] References Cited UNITED STATES PATENTS 3,509,797 5/1970 Johnson425/343 3,180,911 4/1965 Muller 264/119 2,964,077 12/1960 Molla 144/51Primary Examiner-J. Spencer Overholser WWUKEQQMEKTPF Attorneylrvin S.Thomps ofiaiid llohert J. Patch et a1.

[57] ABSTRACT Apparatus for producing wax match shafts, comprising ashaping die having an aperture at least part of which has a polylateral,preferably a quadrilateral, crosssectional configuration with convexsides.

3 Claims, 10 Drawing Figures PATENTEDSEPHIQB 3.758 246 SHEET 2 OF 3APPARATUS FOR PRODUCING WAX MATCH SHAFTS This application is a divisionof copending application Ser. No. 863,948, filed Oct. 6, 1969, now US.Pat. No. 3,626,047.

This invention relates to wax matches.

For the purpose of this specification, the term wax match" includes anymatch whose shaft is composed of combustible sheet material impregnatedand folded, rolled or otherwise compacted into elongate form.

The shafts of wax matches are normally of circular cross section.

Hitherto, conventional wax matches have suffered from the disadvantagethat their shafts are generally thin and not as rigid as wooden matches.Such a wax match is not as easy to strike as a conventional woodenmatch. Although such wax matches approach the effectiveness of woodenmatches if manipulated correctly, there has been some bias against suchwax matches in certain sectors of the buying public.

This disadvantage has been overcome by increasing the cross-sectionaldimensions of the shafts. Hitherto, the increase in shaft thickness has,however, suffered from the disadvantage that the cost of production isincreased due to the increase in material that is required.

Another disadvantage with conventional wax matches with round shafts, isthat they cannot be produced satisfactorily by means of conventionalautomatic machines used for conventional wooden matches of rectangularcross-section. For example, the mass application of striking heads onthe tips of round shafts is very difficult, if not impossible. It willbe appreciated that this increases the production costs of wax matchesso that they are not as competitive in relation to wooden matches asthey might be.

The difficulty with the mass application of striking heads on roundshafts, arises from the fact that it is standard practice with all matchmaking'plants to insert match shafts into round apertures in holders fordipping into striking material in fluid form, a head of strikingmaterial being formed on the tip of each shaft during dipping.Experience has shown that whereas the rectangular shafts or splints ofconventional wooden matches engage securely in the round holes with thecorners of the shafts firmly engaging the surrounds of the apertures,the same firm engagement cannot be obtained when round shafts areinserted into round apertures. It will be appreciated that if the roundapertures are small enough'to ensure a firm engagement with roundshafts, the insertion of the round shafts into the apertures becomes aproblem and damage to the ends of the shafts occur.

lt hasalso been found that it is not'satisfactory to insert the roundshafts into rectangular apertures.

The obvioussolution to the'problemwould be to produce wax matches withshafts of rectangular crosssectional configuration, but intensiveinvestigation by the applicant has indicated that it isnot so simple toproduce a rectangular wax match shaft. Several foreign wax matchmanufacturers of international repute have directed considerable effortto the production of a rectangular wax match shaft, but to the best ofapplicants knowledge no conspicuous success has been achieved so far. infact, applicant's investigations have indicated that it is generallyaccepted in the wax match art that it is not a practically feasibleproposition to produce a rectangular wax match shaft.

It is an object of the present invention to overcome the abovedisadvantages and to provide a satisfactory and economical apparatus forproducing wax match shafts of rectangular cross-sectional configuration.

The method in connection with which the apparatus according to thepresent invention is used, includes the steps of coating combustiblesheet material with suitable impregnating material; compacting the sheetmaterial into an elongated element of generally rounded cross-sectionalconfiguration; deforming the rounded element to present a polylateralcross-sectional configuration with concave sides; and allowing thedeformed element to expand radially at least to reduce the concavity ofthe sides.

It has been found that if the rounded element is only deformed to arectilinear cross-sectional configuration, there is a tendency for thematerial of the element to expand radially outwardly so that the elementloses its rectilinear configuration and again approaches a roundedcross-sectional configuration. However, by proceeding further anddeforming the element so that it has a polylateral configuration withconcave sides, the tendency for the material of the element to expandradially urges the element back towards a rectilinear configuration.Tests have shown that with the method according to the invention, a neatsubstantially rectilinear polylateral cross-sectional configuration canbe achieved.

The rounded elongated element may be produced in any suitable mannerfrom any suitable combustible sheet material, such as paper, which iscoated with any suitable impregnating material, such as wax, to give thefinished product the required degree of rigidity and combustibility. Anysuitable wax or a combination of waxes or a combination of at least onewax and any other suitable material may be used as impregnatingmaterial.

Preferably, the sheet material is first folded upon itself and is thenpassed through one or more dies to compact it and form it into anelongated element of rounded cross-sectional configuration.

The sheet material may be coated with impregnating material at anysuitable stage or stages before, during and/or after the folding andcompacting steps so that the folds of the rounded elongated element aresuitably impregnated to hold them in position.

The rounded element may be deformed into polylateral configuration inany suitable manner, such as by passing the element'through one or moreshaping dies.

Preferably, the rounded element is deformed progressively to the concavepolylateral configuration. The element may accordingly be deformed topresent a rectilinear polylateralcross-sectional configuration prior tobeing deformed into the concavepolylateral configuration.

The rounded element may be deformed to present a polylateralcross-sectional configuration with convex sides prior to being deformedinto the rectilinear crosssectional configuration.

- Preferably, the deformed element of concave polylateral configurationis allowed to expand to a substantially rectilinear configuration.

In a preferred embodiment of the invention, the element is deformed topresent a quadrilateral crosssectional configuration and it is preferredto have a substantially rectangular shaft after the concaveconfiguration has been allowed to expand radially.

A continuous element or an element of considerable length may be formedand then cut into required lengths to produce individual shafts, afterthe element has been deformed into concave polylateral configuration.

According to the invention, the wax match shaft producing apparatusincludes means operative to receive a travelling web of combustiblematerial and fold it laterally upon itself; means operative to receiveand compact the folded web into an elongated element of generallyrounded cross-sectional configuration; at least one shaping die locateddownline of the compacting means, the shaping die presenting an apertureat least part of which has a polylateral cross-sectional configurationwith concave sides; and feed means operative to pass the web ofcombustible material through the folding and compacting means and theresultant rounded element through the shaping die.

At least one additional shaping die may be located ahead of the shapingdie with the convex polylateral aperture, the additional shaping diepresenting an aperture at least part of which has a rectilinearpolylateral cross-sectional configuration.

At least one further shaping die may be located ahead of the die withthe rectilinear polylateral aperture, the further shaping die presentingan aperture at least part of which has a polylateral cross-sectionalconfiguration with convex sides.

Preferably, the dimensions across corners of the polylateral aperturesof all the shaping dies are substantially equal.

The apparatus may further include cutting means downline of the shapingdie with the convex polylateral aperture, the cutting means comprisingan anvil operative to receive and support an elongated element passingfrom the shaping die and presenting a cutting edge lying in a firstplane; and at least one rotary blade which presents a cutting edge andwhich is fast with and extends radially from a drive shaft, a face ofthe blade being opposed to the first plane and lying in a second planedisposed at an acute angle to the first plane with the two planesconverging in the direction of rotation of theblade and the cutting edgeof the blade lying in a rotational plane locatedadjacent the cuttingedge of the anvil.

The 'inventionincludes dies as set out above which are adapted for usewith the apparatus as set out above.

A preferred embodiment of the invention will now be described by way ofexample with reference to the accompanying drawings in which:

FIG. 1 is a diagrammatic side view of apparatus suitable for carryingout the method according to the invention.

FIG. 2 is a perspective view of a folding device of the apparatus of.FIG. 1, operative to fold a travelling web of combustible material uponitself.

F IG. 3 is a perspective view of a further folding device which islocated downline of the device of FIG. 2 and is operative to fold thetravelling web further.

FIG. 4 is a perspective view of yet another folding device which islocated downline of the device of FIG. 3 and is operative to fold thetravelling web still further upon itself.

FIG. 5 is a perspective view, partly in section, of a compacting diewhich is located downline of the device of FIG. 4 and is operative tocompact the folded web into an elongated element of roundedcross-sectional configuration.

FIG. 6 is a perspective view, partly in section, of a shaping dielocated downline of the compacting die of FIG. 5 and operative to deformthe rounded element to present a quadrilateral cross-sectionalconfiguration with convex sides.

FIG. 7 is a perspective view, partly in section, of another shaping dielocated downline of the shaping die of FIG. 6 and operative to deformthe element further to present a rectangular cross-sectionalconfiguration.

FIG. 8 is a perspective view, partly in section, of yet another shapingdie located downline of the shaping die of FIG. 7 and operative todeform the element further to present a quadrilateral cross-sectionalconfiguration with convex sides.

FIG. 9 is a side view, partly in section, of cutting means locateddownline of the shaping die of FIG. 8 and operative to sever acontinuous element passing from the shaping die of FIG. 8 intoindividual shafts of required length.

FIG. 10 is a perspective view to a larger scale of the cutting means ofFIG. 9.

A web 1 of combustible paper passes from a supply roll 2 roundtensioning rolls 3 and into a molten wax bath 4. The folding devices 5,6 and 7 of FIGS. 2, 3, and 4 respectively and the compacting die 8 ofFIG. 5, are located in sequence in wax bath 4. Folding device 5comprises a trapezium-shaped sheet of metal with its corners 5a bentover in the manner shown in FIG. 2. Folding device 7 is of similarconstruction. Folding device 6 presents U-shaped folding aperture 6awhich extends therethrough.

Web 11 is received as a flat sheet of material by folding device 5 andis folded along opposite sides upon itself as it passes through device 5to a folded web la, as can be seen from FIG. 2. Web 1a is received byfolding aperture 6a of device 6 and is folded into the U-shaped web 112,as it passes through device 6, as can be seen from FIG. 3. Initiallywhen the web is threaded through the various devices when the apparatusis set up, web 1a is folded into U-shape by hand and is passed throughfolding aperture 6a. The U-shaped web lb is received by folding device 7and folded still further toweb 10 as it passes through device 7, as canbe seen from FIG. 4. Initially when the apparatus is set up, folded weblb is folded by hand into the formation of web 1c and passed throughdevice 7. Once the apparatus is started up, the

web is fed through continuously and is folded autom ati-' cally.

As the web passes through wax bath 4 in flat and folded form, the webbecomes coated with and the folds impregnated in wax.

The folded web 10 passes from folding device 7 to compacting die 8 whichpresents a bore 9 having a converging and serrated entry zone 90, acentral compacting zone 9b of substantially uniform circular crosssection, and a flared outlet zone 9c. As web 1c passes through entryzone 91:, it is progressively compacted to the size of the central zone9b and the serrations crimp the material of the folded web 10 so that itis compressed in longitudinally fluted fashion. The compression isconsolidated in central zone 9b and a continuous, elongated element 10of generally rounded crosssectional configuration emerges from die 8. Asthe rounded element 10 emerges from die 8, it is coated with an externalwax layer 11.

If required, the rounded element 110 may be passed through one or morefurther compacting dies (not shown) in wax bath 4. After passing fromthe compacting die or dies, the rounded element lit passes from wax bath4 and through a second wax bath 12 to ensure a satisfactory external waxcoating on the element.

From the second wax bath l2, rounded element passes through coolingwater bath 13 to set the wax coating. Upon leaving the water bath 13,the cooled element 10 is subjected to a mechanical shaking operation bya rotary beater 14, to dislodge water adhering to the element.

So far the apparatus and method are conventional for the production of aconventional round wax match shaft.

From water bath l3, rounded element 10 passes over support rollers 15a,15b, 15c, l5d,l5e, and through shaping die 16 of FIG. 6, two shapingdies 117a, 117b, similar to die 17 of FIG. 7 and shaping die 18 of FIG.8 which are located in sequence to deform the rounded element 10progressively. Shaping dies 16, 17a, 17b and 18 are steam heated torender the wax on element 10 plastic. Drip trays 19 are providedunderneath the shaping dies.

Shaping die 16 presents an aperture 20 with a circular entry portion 20ahaving a flared receiving mouth, a deforming portion 2% having aquadrilateral crosssectional configuration with convex sides 21, and aconnecting portion 20c which converges from entry portion 20a todeforming portion 20b and which changes in cross-sectional configurationfrom that of circular entry portion 200 to that of quadrilateraldeforming portion 20b.

It will be appreciated that as the element 10 passes through deformingportion 20b of shaping die 16, the rounded configuration is deformed toa quadrilateral configuration with convex sides which is complementaryto the concave configuration of deforming portion 20b. When it leavesshaping die 16, the deformed element 10a expands radially and assumes acrosssectional configuration approaching a rounded configuration.

Shaping dies 17a, 17b are similar in construction to shaping die 16 withthe exception that the deforming portion 22b of aperture 22 isrectangular in crosssectional configuration with straight sides 23. Asthe element passes through each of shaping dies 17a, 17b, the convexquadrilateral configuration is deformed to a rectangular configuratiomWhen 'it leaves each of shaping dies 17a, 17b deformed element 10b againexpands radially towards a rounded configuration but it will beappreciated that with each deforming step, the expanded configurationcomes closer to being rectangular.

Shaping die 18 is similar in construction to shaping die 16 with theexception that 'the deforming portion 25b of aperture 25 has aquadrilateral cross-sectional configuration with concave sides 26. Asthe element passes through shaping die 18 it is deformed to aquadrilateral cross-sectional configuration with concave sides. When thedeformed element 100, leaves shaping die 18, it again expands radiallyto reduce the concavity of the sides. By carefully relating the degreeof compaction of the elongated element and the precise crosssectionalconfiguration of the deforming portions of the shaping dies, as will bewithin the competence of a skilled man in the art, the degree of radialexpansion of shown in FIG. 8.

The dimension x across corners is the same for the quadrilateraldeforming portions of the apertures of all the shaping dies 16, 17a,E712 and 18.

Downline of the last shaping die 18 is a pair of feed rolls 27' betweenwhich the rectangular elongated element 10c passes on its way to cuttingmeans 28. Through frictional engagement with elongated element 10c, feedrolls 27 continuously draw web 1 off supply roll 2, continuously drawthe folded web through the folding and compacting means in wax bath 4and continuously draw the elongated element 10 through second wax bath12, through water bath l3 and through shaping dies 16, 37a, 17b and 18,before feeding the elongated element to cutting means 28.

Support rolls 15, feed rolls 2'7 and rotary cutting means 28 are drivenfrom common drive motor 29. In order to avoid tension being set up inthe elongated element 10 as it passes through shaping dies 16, 17 and18, first support roll 15a has the greatest speed of rotation, the speedof the succeeding support rolls decreasing progressively with roll 15ehaving the slowest speed of rotation which is equal to that of feedrolls 27.

So far, the apparatus has been described for the production of a singleelongated element It). It will be appreciated that the apparatus may beadapted simultaneously to produce a plurality of juxtaposed elongatedelements.

FIGS. 9 and 10 illustrate rotary cutting means adapted to handle aplurality of elongated elements We simultaneously.

As shown in FIGS. 9 and 110, the cutting means 28 comprises a stationaryplate 30 presenting a plurality of apertures 31 through each of which anelongated element we can pass from feed rolls 27. The surrounds of eachaperture 31 constitute an anvil adapted to receive and support anelongated element for severing. The outer edge of each aperture 31 onthe side opposite feed rolls 27 constitutes a cutting edge lying in theplane of the outer face 300 of plate 30.

A pair of cutting blades 32 with cutting edges 32a are fast with andextend radially in opposite directions from drive shaft 33 which isrotatably coupled to drive motor 29. The blade cutting edges 32a lie inrotational planes located adjacent the plane of the outer surface 30a ofplate 30 so that upon rotation, blade cutting edges 32a successivelypass the anvil cutting edge at the outer end of each aperture 31 tosever an elongated element 10c extending therethrough into individualmatch shafts 34. The circumferential spacing between blade edges 32a,the speed of rotation of blades 32 and the rate of forward feed ofelongated elements 10c, are related so that a match shaft 34 of requiredlength is cut off each time a blade edge 32a passes an aperture 31 inplate 30 through which an elongated element 10c extends.

As can be seen from FIG. 9, the inner face 32b of each blade 32 lies ina plane disposed at an acute angle to the plane of the outer face 30a ofplate 30 with the planes converging in the direction of rotation of theblades 32. The reason for this is that if blades 32 were locatedparallel to plate 30, the end of a continuously moving elongated elementwe emerging from an aperture 31 in plate 30 after it has been severed bythe leading cutting edge 32a of a blade, would tend to contact the innerface 32b of the blade which is opposed to the outer face 30a of plate30. This would render the emerging end of the elongated element Weliable to damage which could cause problems during subsequent stages inthe manufacturing of matches from severed shafts and/or could yieldfinished matches of inferior quality.

With the arrangement of FIG. 9 in which the inner faces 32b of blades 32lie at angles to the outer face Ella of plate 30, the spacing between ablade 32 and plate 30 increases rearwardly with the result that afterthe leading cutting edge 32a of a blade passes an aperture 31 in plate30, successive zones of the blade moving past the aperture 31 movesfurther away from the outlet end of the aperture 31 and remains clear ofthe emerging end of an advancing elongated element 10c.

It will be appreciated that many variations in detail are possiblewithout departing from the scope of the appended claims. For example,the number of apertures 31 in plate 30 of cutting means may be changedto suit the number of elongated elements required to be producedsimultaneously. Thus, plate 30 may have only one aperture 31.

The apparatus may be provided with a positive variable speed drive unitbetween cutting means 28 and the remainder of the apparatus so thatindividual match shafts 34 of variable length can be cut off without anyadjustment to the apparatus being required, other than an adjustment ofthe ratio of the variable speed drive unit to vary the speed of rotationof cutting blades 32.

Instead of severing elongated element 100 into individual shafts 34immediately after the elongated element leaves final shaping die 18, theelement 10c may be suitably wound for subsequent cutting by separatecutting means using a rotary or reciprocating knife or knives.

It will be appreciated that instead of producing match shafts ofsubstantially rectangular cross-sectional configuration, shafts havinganysuitable rectilinear polylateral cross-sectional configuration suchas triangular,

pentagonal or hexagonal may be produced by using shaping dies similar todies 16, 17 and 18 having apertures with deforming portions of suitablecrosssectional configurations.

Where a match shaft having a thickness commensurate with that of aconventional wooden match is required, it is current practice to use twoor more superimposed layers of sheet material in order to obtain anelongated element of required thickness.

The thickness of the end product may be increased by increasing thewidth of the sheet material instead of increasing the thickness of thesheet material by the superimposition of two or more sheets. Byincreasing the width of the sheet material, material of inferiorstrength to that which is currently required, may be used without anydanger of the sheet material breaking. As a result, a saving in the costof the end product without any sacrifice in its quality may be achieved.

Tensioning rolls 3 permit the use of materials of relatively low tensilestrength but are not essential and may be omitted where material ofsuitable strength is used. Where tensioning rolls 3 are omitted, thefirst zone along the production line where tension is applied to the webof sheet material and the resultant elongated element, is at the firstsupport roll 15a.

it has been found that a match shaft produced by apparatus in accordancewith the invention engages firmly and satisfactorily with roundapertures in a dipping holder and that the mass application of strikingheads to the tips of individual shafts is facilitated.

The invention permits the production of wax matches which arecommensurate in shape, dimensions and rigidity with conventional woodenmatches and which is competitive in price.

It has been found that a wax match according to the invention can bemade satisfactorily and economically by means of conventional automaticmatch making machines.

i-iaving described my invention, 1 claim:

1. Wax match shaft producing apparatus comprising a molten waxcontainer; folding means located in the container and operative toreceive and fold a travelling web of combustible material laterally uponitself; a compacting die located in the container and operative toreceive and compact the folded web into an elongated element ofgenerally rounded cross-sectional configuration; a first shaping dielocated downline of the compacting die and presenting an aperture atleast part of which has a polylateral cross-sectional configu-' rationwith convex sides; a second shaping die located downline of the firstshaping die and presenting an aperture at least part of which has arectilinear polylateral cross-sectional configuration; a third shapingdie located downline of the second shaping die and presenting anaperture at least part of which has a polylateral cross-sectionalconfiguration with concave sides; and severing means located downline ofthe third shaping die and operative to sever a continuous elementpassing from the third shaping die into individual match shafts.

2. Wax match shaft producing apparatus comprising means for coatingcombustible sheet material with liquid impregnating material, meansfolding the sheet material to reduce the width thereof, means compactingthe folded sheet material into an elongated element of generally roundedcross-sectional configuration, and means deforming the rounded elementto present a polylateral cross-sectional configuration with concavesides and for permitting the deformed element to expand radially atleast to reduce'the concavity of the sides.

3. Wax match shaft producing apparatus comprising means feeding a web ofcombustible material through molten wax, means folding the web laterallyupon itself as it travels through the molten wax, means compacting thefolded web into an elongated sheet of generally rounded configuration asit travels through the molten wax, means deforming the rounded element.to present a polylateral cross-sectional configuration with convexsides, means deforming the resultant element to prescut a rectilinearpolylateral cross-sectional configuration, means deforming the resultantelement to present a polylateral cross-sectional configuration withconcave sides and allowing the resultant element to expand radially to asubstantially rectilinear configuration, and means severing the expandedelement into individual match shafts.

i i t t '3

1. Wax match shaft producing apparatus comprising a molten waxcontainer; folding means located in the container and operative toreceive and fold a travelling web of combustible material laterally uponitself; a compacting die located in the container and operative toreceive and compact the folded web into an elongated element ofgenerally rounded cross-sectional configuration; a first shaping dielocated downline of the compacting die and presenting an aperture atleast part of which has a polylateral cross-sectional configuration withconvex sides; a second shaping die located downline of the first shapingdie and presenting an aperture at least part of which has a rectilinearpolylateral cross-sectional configuration; a third shaping die locateddownline of the second shaping die and presenting an aperture at leastpart of which has a polylateral cross-sectional configuration withconcave sides; and severing means located downline of the third shapingdie and operative to sever a continuous element passing from the thirdshaping die into individual match shafts.
 2. Wax match shaft producingapparatus comprising means for coating combustible sheet material withliquid impregnating material, means folding the sheet material to reducethe width thereof, means compacting the folded sheet material into anelongated element of generally rounded cross-sectional configuration,and means deforming the rounded element to present a polylateralcross-sectional configuration with concave sides and for permitting thedeformed element to expand radially at least to reduce the concavity ofthe sides.
 3. Wax match shaft producing apparatus comprising meansfeeding a web of combustible material through molten wax, means foldingthe web laterally upon itself as it travels through the molten wax,means compacting the folded web into an elongated sheet of generallyrounded configuration as it travels through the molten wax, meansdeforming the rounded element to present a polylateral cross-sectionalconfiguration with convex sides, means deforming the resultant elementto present a rectilinear polylateral cross-sectional configuration,means deforming the resultant element to present a polylateralcross-sectional configuration with concave sides and allowing theresultant element to expand radially to a substantially rectilinearconfiguration, and means severing the expanded element into individualmatch shafts.